Modular molding assembly

ABSTRACT

A molding apparatus defining a processing direction includes multiple molding modules spaced apart in a lateral direction perpendicular to the processing direction and a common reaction surface. Each molding module includes a frame and a mold roll that defines molding cavities. Each mold roll defines a respective pressure zone in cooperation with the reaction surface and each mold roll is movable with respect to the reaction surface by controlled operation of the frame. Molten resin is introduced into the pressure zones and forced into the molding cavities to form arrays of fastener elements extending from base layers of resin formed on the surfaces of the mold rolls. The fastener elements are withdrawn from the cavities while stripping the base layers from the peripheral surfaces.

TECHNICAL FIELD

This invention relates generally to equipment and methods for makinglongitudinally continuous products with limited arrays of moldedprojections, such as fastener elements.

BACKGROUND

Roll-forming processes are employed to mold resin into various products,including to mold continuous flexible strips of resin with arrays ofprojections extending from one side of a base layer. In some cases, thestrips are formed permanently laminated to a flexible substrate, such asby running the substrate through a molding nip with molten resin, andpressing the resin into cavities of a molding roller. The resin can beintroduced to the roller in separate streams, so as to mold spacedstrips on the substrate.

Improvements in methods of making products of different desiredconfigurations, and in the equipment for performing such methods, aredesired.

SUMMARY

One aspect of the invention features a molding apparatus that defines aprocessing direction. The molding apparatus includes a reaction surfaceand multiple molding modules. The molding modules are spaced apart in alateral direction perpendicular to the processing direction, forsimultaneous molding in respective regions associated with the modules.Each molding module includes a frame and a rotatable roller coupled tothe frame. The rotatable roller defines in cooperation with the reactionsurface a respective pressure zone. At least one of the reaction surfaceand rotatable roller defines an array of molding cavities. The rotatableroller of each molding module is independently movable with respect toproximity to the reaction surface by controlled operation of the frameof the molding module.

In some examples, the molding apparatus further includes at least oneresin source configured to introduce molten resin into the pressure zoneto be forced into the molding cavities by pressure in the pressure zone.In some examples, each molding module includes a respective resinsource. In some cases, the resin source is configured to supply acontinuous flow of resin to the pressure zone, for forming a continuouslayer of resin. In some cases, the resin source is configured to supplymolten resin in discontinuous quantities, for forming an interruptedlayer of resin.

In some embodiments, the molding modules are arranged to mold resin ondifferent portions of one or more substrates moving between the rollerand the reaction surface. In some arrangements, the molding modules arearranged to mold resin on a common surface of a substrate moving betweenthe rollers and the reaction surface. In some cases, each molding moduleis configured to apply pressure to a first region of the substrate inthe pressure zone, while a second region of the substrate is locatedbetween two pressure zones.

In some arrangements, the molding cavities are shaped to form discretestems extending from a layer of resin formed between the reactionsurface and the rotatable roller. In some examples, the molding cavitiesare shaped to form touch fastener elements with heads overhanging thelayer of resin. In some examples, the molding apparatus includes atleast one knock-down roller arranged to level the fastener elementsuniformly with respect to the layer of resin. In some cases, the moldingapparatus includes multiple knock-down rollers, with each knock-downroller associated with a corresponding molding module.

In some examples, the reaction surface includes a surface of a rotatablepressure roll. In some examples, the pressure zone between the rotatableroller and the pressure roll includes a nip into which resin is drawnunder shear force developed by rotation of the pressure roll. In somecases, the rotatable roller is a passive roller that is configured to bedriven at least in part by movement of the pressure roll. In some cases,the molding apparatus further includes a drive roll spaced from thepressure roll. The drive roll is configured to engage an outer surfaceof the rotatable roller through resin disposed on the outer surface.

In some embodiments, the molding apparatus further includes a substratefeeder arranged to feed a flexible substrate into the pressure zonesbetween the rotatable rollers and the reaction surface, for laminationof the molten resin onto the flexible substrate in at least one of thepressure zones during molding of resin in the arrays of cavities. Insome cases, the molding apparatus further includes at least onedeflector shoe arranged between rotatable rollers, limiting separationof the substrate from the reaction surface. In some arrangements, themolding apparatus includes multiple deflector shoes, with each shoesecured to the frame of a respective molding module.

In some examples, each rotatable roller is also independently movablewith respect to the reaction surface in a lateral direction parallel toa rotation axis of the roller. In some cases, each rotatable roller islaterally movable by laterally moving its molding module.

In some arrangements, the rotatable roller defines the array of moldcavities in a peripheral surface of the rotatable roller.

In some cases, the molding module further includes, for each moldingmodule, a linear actuator operable to move the rotatable roller withrespect to the reaction surface.

Another aspect of the present disclosure features a method of molding afastener product along a processing direction. The method includespositioning multiple molding modules with respect to a common reactionsurface, so that each module has a respective mold roll forming arespective pressure zone in cooperation with the reaction surface. Thepressure zones are spaced apart along the common reaction surfaceaccording to the positioning of the modules. Each of the mold rolls hasa peripheral surface and defines an array of cavities that extend intothe mold roll from the peripheral surface. The method further includesintroducing molten resin separately into each pressure zone. The resinis introduced such that during rotation of the mold rolls with respectto the reaction surface, the introduced resin is forced into thecavities in the pressure zones to form arrays of projections. The arraysof projections extend from base layers of resin formed on the peripheralsurfaces of the mold rolls. The method further includes withdrawing theprojections from the cavities while stripping the base layers from theperipheral surfaces.

In some examples, the projections include molded fastener elements.

In some arrangements, the method further includes, after withdrawing theprojections, plastically deforming the projections to form fastenerelements.

In some cases, positioning each molding module includes moving themodule in a direction perpendicular to the processing direction. In someexamples, positioning each molding module further includes, after movingthe module in the direction perpendicular to the processing direction,moving the mold roll of the module toward the reaction surface. In somecases, moving the mold roll toward the reaction surface includes firstmoving the mold roll at a relatively fast rate and then moving the moldroll at a slower rate.

In some arrangements, the method further includes positioning asubstrate between the molding modules and the common reaction surface,such that as the resin is forced into the cavities in the pressurezones, the resin is laminated to the substrate to form the base layersas layers spaced apart by exposed regions of the substrate. In someexamples, the method further includes repositioning the molding modulesduring a pause in the introduction of molten resin, to alter a spacingof the base layers on the substrate. In some cases, the method furtherincludes limiting separation of the substrate from the reaction surfaceby using at least one deflector shoe coupled to the molding modules.

In some examples, the reaction surface includes a driven pressure rollarranged so that, during introduction of the molten resin, drivenrotation of the pressure roll causes rotation of the mold roll. In somecases, the method further includes a drive roll spaced from the pressureroll so that, during introduction of the molten resin, driven rotationof the drive roll causes rotation of the mold roll in cooperation withthe pressure roll.

Various implementations of the invention can be configured so as toenable particularly efficient molding of resin projections, either onseparate base layers or on layers connected by a common flexiblesubstrate. The modular arrangement allows the molding equipment to bequickly reconfigured without having to remove or disassemble heavy,delicate molding rolls, and sometimes even with a substrate threadedthrough the equipment. The arrangement of separate molding rolls againsta common reaction surface, such as a pressure roll, can reduce some ofthe undesired effects of bending long mold rolls under extreme nippressures, and can allow for the in-process adjustment of moldingparameters (e.g., base layer thickness, nip pressure) across a singleproduct. Such adjustment can even be used to reduce the effects ofpressure roll bending. Other advantages will also be evident from thefollowing description of examples.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a molding apparatus having two moldingmodules.

FIG. 1B is a side elevation view of the molding apparatus of FIG. 1A anda method for laminating resin onto a pleated product.

FIG. 1C is an enlarged view of area 1C in FIG. 1B.

FIG. 2 is a perspective view of a section of the molding apparatus ofFIG. 1A with the molding modules in a disengaged position.

FIG. 3A is a perspective front view of a molding module assembly.

FIG. 3B is a perspective back view of the molding module assembly ofFIG. 3A.

FIG. 4 is a schematic side view of the molding apparatus, showing anextrusion head attached to the molding module.

FIG. 5 is a schematic illustration of an apparatus and method forpositioning a rotatable roller with respect to a pair of processingrollers for molding resin.

FIG. 6 is an enlarged, partial cross-section view through the rotatableroller, showing molding cavities.

FIG. 7 is a partial front view of the rotatable roller showing ringsthat form the molding cavities.

FIG. 8 is a perspective view of a deflector shoe.

FIG. 9 shows a section of a molding module with a pair of deflectorshoes mounted on a frame of the molding module, with each shoe securedto one side of the rotatable roller.

FIG. 10 illustrates the use of the removable deflector shoes.

Common reference numbers in different figures indicate similar oridentical elements.

DETAILED DESCRIPTION

Referring to FIG. 1A, a molding apparatus 10 for producing fastenerproducts features two molding modules 100 a and 100 b inside aprocessing enclosure 16. Each molding module includes a base 102, aframe 104, a rotatable roller 106, a resin extrusion head 112, and alinear actuator 108 (e.g., a drive cylinder). The molding modules 100 aand 100 b are positioned to mold resin in collaboration with a pair ofspaced-apart, fixed-axis processing rollers 12 and 14. The processingrollers 12 and 14 are mounted on chamber 16 and are driven about theirrespective axes by a motor 28 such as a direct drive motor, a belt drivemotor, or a combination of the two. Each roller can be driven by arespective motor. The processing rollers form a gap between them,through which gap molding modules 100 a and 100 b extend. Duringoperation, structural base 102 is fixed in position with respect to theprocessing rollers axes, while frame 104 can move along the length ofbase 102. Each base 102 is slidably mounted on a bench 26 that is fixedto chamber 16, allowing its respective molding module to be moved in alateral direction parallel to the rotation axes of the processingrollers. While only two modules are shown in this example, moldingapparatus 10 may include more than two molding modules, such as three,four, or even five or more modules.

Referring also to FIGS. 1B and 1C, molding apparatus 10 defines aprocessing direction 25 and performs a continuous extrusion/roll-formingmethod for forming fastener elements 20 on an integral, resin sheet-formbase 19. Extrusion head 112 is attached to a bottom end of base 102 andsupplies a sheet of molten resin (not shown) to a pressure zone ormolding nip 22 defined between rotatable roller 106 and processingroller 12, which functions both as a reaction surface and a drive roll.

Rotatable roller 106 is attached to a distal end of frame 104, and byoperation of the frame the roller 106 is movable toward and away fromboth rollers 12 and 14. Rotatable roller 106 (sometimes referred toherein as mold roll), defines an array of miniature, molding cavitiesextending inward from its periphery 111 for molding fastener elements20. The pressure in nip 22 forces resin to enter and fill the exposedmolding cavities, while excess resin forms base 19 on the peripheralsurface of the mold roll and interconnects the filled cavities that formfastener elements 20. Mold roll 106 is continuously cooled, e.g., bycontrolled flow of coolant through its interior, heat is extracted fromthe product as the product passes through first nip 22 and travels to asecond nip 24 between mold roll 106 and processing roller 14, whichfunctions as a counter-rotating drive roll. Alternatively, processingrollers 12 and 14, or an external source, can provide cooling to themolten resin, as the only cooling source or in collaboration with moldroll 106. The heat removal solidifies fastener elements 20 (e.g.,hooks), subsequently allowing elements 20 to be peeled from their fixedcavities by drive roll 14, also referred to as a take-off roll. Hooks 20are then leveled uniformly by a knock-down roller 114 attached tostructural base 102. Alternatively, mold roll 106 can be configured toform arrays of projections (e.g., straight stems) extending from base 19that are peeled from the cavities of mold roll 106 and plasticallydeformed by a knock-down roller to form the fastener elements.

Referring also to FIG. 2, in a non-operating position the moldingmodules 100 a and 100 b are disengaged from processing rollers 12 and14. To disengage molding modules 100 a and 100 b, each frame 104 a and104 b independently moves along its respective base 102 a and 102 b toposition the mold rolls 106 a and 106 b away from the processing rollers12 and 14.

As shown in FIG. 1B, a substrate 18, shown in dashed lines, may betrained about the rollers in order to mold resin on a surface ofsubstrate 18. Substrate 18 is preferably a non-woven fabric. To start upthe machine, frame 104 moves mold roll 106 away from processing rollers12 and 14, and substrate 18 is then positioned about the processingrollers and mold roll 106, extending in the processing direction 25.When frame 104 moves mold roll 106 in position against pressure roll 12and drive roll 14, with resin between the rollers in the nips, theapparatus is configured to mold fastener elements while laminating resinbase 19 to the surface of substrate 18. Substrate 18 is laminated to theresin in pressure nip 22 and is carried about mold roll 106 with thesolidifying resin. Substrate 18 is then stripped from mold roll 106 atnip 24 with the solidified resin, and exits molding apparatus 10 as thefastener product shown in FIG. 1C.

Pressure roll 12 and drive roll 14 rotate in the same direction and,when in engagement with mold roll 106, both rollers drive mold roll 106to rotate. Mold roll 106 is a passive roller, only rotating by movementof pressure roll 12 and drive roll 14. Drive roll 14 engages outersurface 111 of mold roll 106 through resin base 19 on outer surface 111,and pressure roll 12 engages mold roll 106 through the resin droppedinto nip 22. When molding on a substrate, the rollers also engagethrough the thickness of the substrate in the nips. As shown in FIG. 2,when the frame is extended, the mold roll is spaced from the processingrollers and readily accessible to be changed or serviced. This positionalso allows other components of apparatus 10 such as the processingrollers 12 and 14 or the frames to be serviced or removed formaintenance, or for a substrate to be threaded between the rolls duringsetup.

As shown in FIGS. 1A and 2, pressure roll 12 and drive roll 14 havegenerally the same length, both rollers being longer than mold roll 106and knock-down roll 114. Each molding module 100 a and 100 b isrelatively narrow, and, each can be moved independently in a lateraldirection parallel to its mold roll axis. This movement is preferablydone with the mold roll retracted, but can also be done during molding.This flexibility allows each mold roll 106 a and 106 b to be placed indifferent locations along the length of pressure roll 12, so that eachmodule can apply resin at any selected position across the width of oneor more substrate sheets.

Referring now to FIGS. 3A and 3B, molding module 100 has a structuralbase 102 with a U-shaped channel with two opposite walls 101 a and 101b, a bottom plate 115 connecting both sides at a distal, bottom end, anda pair of linear bearings 117 attached to the back of the U-shapedchannel. Each wall 101 a and 101 b defines an open slot 107 in themiddle, and a corner piece 129 attached at a distal, upper end. At oneend of open slot 107, each wall 101 a and 101 b forms an L-shapedstructure 118 connected to a linking arm 116 that carries the knock-downroll 114. Base 102 has a rail connection (not shown) between both walls101 a and 101 b that receives frame 104. Linear bearings 117 areconfigured to be slidably retained within rails of bench 26 (as in FIG.1A), and together form a linear bearing guide that allows the moldingmodule 100 to move laterally.

Knock-down roll 114 is mounted on linking arm 116 that is connected tobase 102. Linking arm 116 biases knock-down roll 114 downward againstthe take-off roll by virtue of a spring loaded shaft connection 154 withinternal torsion springs and/or linear springs, with a positive stopthat can be adjusted to set a desired gap. The pressure applied byknock-down roll 114 to the drive roll pushes down against the fastenerelements to level them, making the fastener product more uniform.Knock-down roll 114 need only be of sufficient width to engage thefastener elements molded by mold roll 106.

Corner piece 129 is made of a rigid material such as carbon steel andfeatures two exposed surfaces: a side surface 126 and back surface 128,defining between them a corner 130. Side surface 126 and back surface128 are both straight, with back surface 128 being generallyperpendicular to side surface 126. Alternatively, back surface 128 canbe curved or otherwise profiled, and/or extend in a different direction,such as forming an obtuse or an acute angle with side surface 126.Corner piece 129 is permanently secured to the rest of base 102.

Frame 104 has three parts: an internal rail 103 and two externalmounting arms 105. Internal rail 103 is a long plate that has a top endwith a pin block 138 extending beyond the edges of mounting arms 105when assembled. On a back surface, internal rail 103 defines linearbearing rail connections (not shown) to slidably connect to base 102. Awider part of internal rail 103 extends beyond slots 107 when assembled.Each mounting arm 105 of the frame has recesses 105 a for receivingscrews to connect to internal rail 103. One mounting arm 105 connects toeach side of internal rail 103 such that internal rail 103 is disposedinside base 102 and mounting arms 105 are disposed outside the base.This connection constrains frame 104 against relative motion other thanin a direction parallel to side surface 126 of base 102, along thelength of the slot.

In addition, molding module 100 includes a lever arm 110 that has afirst pivot hole 136 for connecting to pin block 138 and a second pivothole 134 for connecting to drive cylinder 108. Lever arm 110 also hasone end connected to a pair of cam roller bearings 132, such as needlebearings. Roller bearings 132 are coaxially connected to lever arm 110,with one roller bearing 132 on each side of lever arm 110. Pivot hole136 is located between second pivot hole 134 and roller bearings 132along the length of the lever arm. The shape of lever arm 110 can bealtered to adapt for different connections with the drive cylinder, railconnection block and/or roller bearings 132. Alternatively, instead ofroller bearings 132, lever arm 110 can include cam rollers or adifferent object with a bearing surface, including a fixed bearing (cam)surface. Lever arm 110 also includes an additional roller bearing 148coupled to the second pivot 134, to contact a lever support 146 of base102.

In addition, molding module 100 features drive cylinder 108 that ispivotally coupled to base 102. Drive cylinder 108 has a cylinder rod 142and a cylinder barrel 122. Barrel 122 is pivotally connected to base 102at a pivot coupling between L-shaped structures 118, and rod 142 ispinned to lever arm 110 at second pivot hole 134. Alternatively, drivecylinder 108 can be mounted in the opposite direction, with rod 142connected to the base and barrel 122 connected to lever arm 110,disposed above the lever arm, on an opposite side of the lever arm asthe mold roll. Drive cylinder 108 may be any type of controllable linearactuator, such as a pneumatic or hydraulic cylinder actuated under fluidpressure, a ball screw actuator, or a linear motor.

To move frame 104 along base 102, drive cylinder 108 is actuated to movelever arm 110, which travels along corner piece 129. Starting when drivecylinder is in a retracted position, lever arm 110 is positionedlongitudinally parallel to side surface 126. When drive cylinder 108extends cylinder rod 142, roller bearings 132 roll along corner piece129, moving from side surface 126, around the corner 130, to backsurface 128 of corner piece 129. During this motion, lever arm 110 movesframe 104 with respect to base 102 over a linear stroke of drivecylinder 108 that moves second pivot 134 along a continuous motion path.More specifically, as lever arm 110 moves over the linear stroke ofcylinder 108, frame moves mold roll 106 toward pressure roll 12 anddrive roll 14 (FIG. 1B), applying pressure to both rollers 12 and 14.This happens in a two-step process, starting with the frame 104 extendedand the mold roll disengaged (as in FIG. 2). First, motion along a firstpath segment of the lever arm brings mold roll 106 into close proximitywith pressure roll 12 and drive roll 14, under no appreciableresistance. Second, as drive cylinder 108 continues to extend, movingthe lever arm along a second path segment and continuing to raise therail member, mold roll 106 is moved into closer proximity with pressureroll 12, but at a slower rate. Once in position for molding, mold roll12 can apply sufficiently leveraged force to resin in the molding nip togenerate the necessary nip pressure to fill the mold cavities and togenerate enough torque from rotation of the driven rolls to causerotation of the mold roll. During molding, nip pressure can becontrolled by cylinder motion, increasing nip pressure by extendingcylinder rod 142 and decreasing nip pressure by retracting cylinder rod142. Further details of the cylinder operation and related linkage canbe found in U.S. application Ser. No. 15/797,164, entitled “LinearActuator Leverage” and filed on the same day herewith, the entirecontents of which are incorporated by reference herein.

Lever support 146 helps lever arm 110 move along a continuous motionpath, as lever arm 110 moves from the first path segment to the secondpath segment by allowing cam roller 148 of lever arm 110 to bear againstsupport 146 when roller bearings 132 move along corner 130. Support 146is fixed at a distance from side surface 126, ‘pushing’ lever arm 110toward back surface 128 when lever arm 110 is pivoting to move pastcorner 130 to the second path segment.

Referring now to FIG. 4, extrusion head 112 is connected to a bottom endof base 102, between mounting arms 105 of frame 104. Extrusion head 112includes a nozzle 112 a for introducing molten resin to molding nip 22.The position of head 112 is adjustable such as to position nozzle 112 adirectly above nip 22, such that the extruded molten resin fallsvertically into nip 22 under the force of gravity. Alternatively, head112 can be positioned to drop the molten resin onto a surface ofpressure roll 12 or the surface of mold roll 106, to be carried into nip22 by rotation of the rollers. Head 112 can be configured to introducemolten resin continuously or, when using a substrate, in a series ofdiscrete amounts, to form islands spaced apart longitudinally over thesubstrate to form an interrupted strip of fastener elements.

Referring to FIG. 6, mold roll 106 includes fixed molding cavities 111 afor molding resin, and its periphery is made out of rings, as shown inFIG. 7. Fixed molding cavities 111 a extend inward from periphery 111 ofmold roll 106. Cavities 111 a have a shape specifically designed tofacilitate both complete filling of the cavities as well as relativelyeasy removal of the solidified fastener elements 20. Cavities 111 a areconfigured so that removing or peeling away fastener elements 20 can bedone without opening cavities 111 a. Each cavity 111 a includes a throat111 b having an inwardly tapered configuration, which opens towardperiphery 111, such as to allow the removal of fastener element 20 fromcavities 111 a without breaking or substantially deforming fastenerelements 20.

As shown in FIG. 7, mold roll 106 includes concentric etched or engravedrings 170, and substantially flat spacer rings 172, which togetherdefine molding cavities 111 a within which fastener elements are formed.In this example, each of rings 170 and 172 is provided with an outsidediameter of about 250 mm, and a thickness of about 0.15 to 1.0 mm. Thecavities may only partially extend through a given ring, or may extendfully through a ring and bounded by adjacent surfaces of spacer rings.

FIG. 5 shows mold roll 106 in position to mold fastener elements,cooperatively engaged with the surfaces of both pressure roll 12 anddrive roll 14. Mold roll 106 and pressure roll 12 each have a respectiverotation axis, with both axes being parallel and lying in a commonhorizontal plane ‘g’, such that nip 22 is symmetric about a verticalplane for receiving molten resin dropped from the extrusion nozzle.Alternatively, plane g can be tilted to suit a different configurationof apparatus 10. Each of rolls 12 and 14 has a diameter of, for example,250 mm, with a distance ‘f’ between the rotation axes of pressure roll12 and drive roll 14 of, for example, 438 mm. Wrap angle α is definedfrom the centers of nips 22 and 24 (where lines connecting the rollcenters cross the nips) and represents the included angle of the portionof the mold roll surface over which the resin is cooled and solidified.As mold roll 106 rotates counterclockwise during the molding process,the resin is sufficiently cooled from molding nip 22 to second nip 24 tobe stripped out from cavities 111 a by drive roll 14. Angle α ispreferably between 190° and 300°, such as 240°. As the mold roll isurged toward the pressure and drive rolls during molding, the minimumgap between the pressure and drive rolls will be necessarily less thanthe diameter of the drive roll, and angle α will be always greater than180°. With wrap angle α having a value of 240°, for example, and moldroll 106 having a radius of 250 mm, for example, circumferential coolingdistance e is 531 mm. This implementation allows the product on moldroll 106 to be carried for a longer time, in comparison to an alignedroll stack where angle α is 180°. The greater angle α, the more heat maybe removed from the product, enabling higher run speeds.

Referring now to FIGS. 8 and 9, a deflector shoe 180 has a circularplate 184 with a cylindrical opened ring 182 coupled to the periphery ofplate 184. Ring 182 has an uniformly continuous outer surface with athickness ‘t’ of approximately 25 to 75 millimeters (optimally, sized tofill most of the spacing between adjacent mold rolls) and a diametersimilar to the diameter of mold roll 106, and extends about ¾ of the wayaround the shoe. In some cases, the shoe diameter can be smaller thanthe diameter of mold roll 106. As shown in FIG. 9, cylindrical openedring 182 is configured to receive an end of mounting arm 105, allowingplate 184 to couple to frame 104 adjacent mold roll 106. Shoe 180 formsa narrow gap 196 with mold roll 106. As shown in FIG. 8, circular plate184 has some slots that receive fasteners for connecting to frame 104,and other slots arranged to permit access to a side of mold roll 106when shoe 180 is mounted on frame 104. For example, an open square slot190 and an L-shaped slot 192 allow access to a side of mold roll 106 formaintenance, disassembly, or feeding mold roll 106 with a cooling fluid.Small L-shaped slots 188 and holes 194 receive fasteners for connectingshoe 180 to frame 104, as shown in FIG. 9. In this example, fasteners199 are conventional screws and fasteners 198 are spring loadedfasteners that, when connected, allow shoe 180 to be temporarilyseparated from the frame after conventional screws 199 have been takenout or loosen. This is useful when spring fasteners 198 are not readilyaccessible, allowing the assembly to be disconnected and/or easilyaccessed for maintenance. Details of spring fasteners 198 can be foundin U.S. application Ser. No. 15/728,630, entitled “Threaded Fastening”and filed on Oct. 10, 2017, the entire contents of which areincorporated by reference herein.

Referring to FIG. 10, three molding modules 100 a, 100 b, and 100 c withshoes 180 are spaced apart laterally and aligned along a directionperpendicular to the processing direction for molding resin onto asubstrate. For clarity, the respective knock-down rollers of eachmodule, and the drive roll, are not shown. A substrate feeder 204, suchas a roll of substrate, feeds a flexible substrate 200 into the pressurezones 22, for lamination of molten resin 202 onto substrate 200. Thelamination takes place in the pressure zones 22 during molding of resin202 in the arrays of mold cavities. Each molding module molds a strip ofresin 202, molding together three strips of resin onto substrate 200.The removable deflector shoes 180 are secured to respective frames 104a, 104 b, and 104 c, and are placed on each side of mold rolls 106 a,106 b, and 106 c. Shoes 180 are arranged to limit separation ofsubstrate 200 from pressure roll 12 as the substrate passes through thenips, keeping substrate 200 from creasing between the mold rolls. Theadjacent shoes 180 that are attached to separate molding modules areseparated by a module separation gap ‘c’ of between 1.0 and 5.0 mm, withthe spacing ‘a’ and ‘b’ between longitudinal centers of adjacent moldrolls, for example, 160 mm respectively. Distances ‘a’ and ‘b’ can bethe same, or the width of each module and/or the separation gaps can bevaried to position the mold rolls as desired for different applications.In addition, shoes 180 can be selectively removed, such as to allowcreasing or puckering of substrate 200 in selected areas betweenpressure zones. In cases where two lanes of fastener resin are requiredvery close to each other on a substrate, a corresponding single modulecan be provided with a roll of multiple cavity regions, with a die thatprovides corresponding, spaced streams of resin to the cavity regions.

A selected number of examples of the invention are described above insome detail. It should be understood that other examples will beapparent from the above description and may fall within the followingclaims.

What is claimed is:
 1. A method of molding a fastener product along aprocessing direction, the method comprising: positioning multiplemolding modules with respect to a common reaction surface, each modulehaving a respective mold roll forming a respective pressure zone incooperation with the reaction surface, with the pressure zones spacedapart along the common reaction surface according to the positioning ofthe modules, the mold rolls each having a peripheral surface anddefining an array of cavities extending into the mold roll from theperipheral surface; introducing molten resin separately into eachpressure zone, such that during rotation of the mold rolls with respectto the reaction surface, the introduced resin is forced into thecavities in the pressure zones to form arrays of projections extendingfrom base layers of resin formed on the peripheral surfaces of the moldrolls; and then withdrawing the projections from the cavities whilestripping the base layers from the peripheral surfaces.
 2. The method ofclaim 1, wherein the projections comprise molded fastener elements. 3.The method of claim 1, further comprising, after withdrawing theprojections, plastically deforming the projections to form fastenerelements.
 4. The method of claim 1, wherein positioning each moldingmodule comprises moving the module in a direction perpendicular to theprocessing direction.
 5. The method of claim 4, wherein positioning eachmolding module further comprises, after moving the module in thedirection perpendicular to the processing direction, moving the moldroll of the module toward the reaction surface.
 6. The method of claim4, wherein moving the mold roll toward the reaction surface comprisesfirst moving the mold roll at a first rate and then moving the mold rollat a second rate slower than the first rate.
 7. The method of claim 1,further comprising positioning a substrate between the molding modulesand the common reaction surface, such that as the resin is forced intothe cavities in the pressure zones the resin is laminated to thesubstrate to form the base layers as layers spaced apart by exposedregions of the substrate.
 8. The method of claim 7, further comprisingrepositioning the molding modules during a pause in the introduction ofmolten resin, to alter a spacing of the base layers on the substrate. 9.The method of claim 7, further comprising limiting separation of thesubstrate from the reaction surface by using at least one deflector shoecoupled to the molding modules.
 10. The method of claim 1, wherein thereaction surface comprises a driven pressure roll, and wherein, duringintroduction of the molten resin, driven rotation of the pressure rollcauses rotation of the mold rolls.
 11. The method of claim 10, furthercomprising a drive roll spaced from the pressure roll, and wherein,during introduction of the molten resin, driven rotation of the driveroll causes rotation of at least one of the mold rolls in cooperationwith the pressure roll.
 12. The method of claim 1, wherein introducingmolten resin comprises introducing the molten resin in discontinuousquantities, thereby forming an interrupted layer of resin.
 13. Themethod of claim 1, wherein the molding modules are arranged to moldresin on different portions of one or more substrates moving between themold rolls and the reaction surface.
 14. The method of claim 1, whereinthe molding modules are arranged to mold resin on a common surface of asubstrate moving between the mold rolls and the reaction surface. 15.The method of claim 1, further comprising, after withdrawing theprojections, knocking down heads of the withdrawn projections to levelthe projections with respect to the layer of resin.
 16. The method ofclaim 1, wherein the reaction surface comprises a surface of a rotatablepressure roll, the method comprising drawing the molten resin into nipsbetween the mold rolls and the pressure roll under shear force developedby rotation of the pressure roll.
 17. The method of claim 1, furthercomprising engaging an outer surface of at least one of the mold rolls,through resin disposed on the outer surface, with a drive roll spacedfrom the pressure roll.
 18. The method of claim 1, further comprisingfeeding a flexible substrate into the pressure zones between the moldrollers and the reaction surface, for lamination of the molten resinonto the flexible substrate in at least one of the pressure zones duringmolding of resin in the arrays of cavities.
 19. The method of claim 18,further comprising limiting separation of the substrate from thereaction surface with at least one deflector shoe arranged betweenadjacent mold rolls.
 20. The method of claim 1, further comprisingindependently adjusting relative positions of the mold rolls withrespect to the reaction surface in a lateral direction parallel torotation axes of the mold rolls.